U.S. patent number 6,615,762 [Application Number 09/938,129] was granted by the patent office on 2003-09-09 for foldable boat with light weight hull construction system.
Invention is credited to William S. Scott.
United States Patent |
6,615,762 |
Scott |
September 9, 2003 |
Foldable boat with light weight hull construction system
Abstract
A primary goal of the present invention is to improve the prior
art assembly system. The present invention provides a boat of
simple ultra light construction with the fewest number of parts
that can be easily assembled without tools. Then, when disassembled
provides a compact lightweight package suitable for long range or
rough terrain portage or back packing. A plastic coated nylon
waterproof cover or like skin can be conveniently slid onto, and
off of the assembled hull and quickly fastened in place to provide
waterproofness for the hull. Another goal of this invention is to
introduce a watercraft construction method whose components can be
made from extruded corrugated plastic and other plastic materials
that are lightweight, but strong, and can be inexpensively mass
produced using rule dies and the like inexpensive tooling and
assembly methods.
Inventors: |
Scott; William S. (Portland,
OR) |
Family
ID: |
27789492 |
Appl.
No.: |
09/938,129 |
Filed: |
August 23, 2001 |
Current U.S.
Class: |
114/353;
114/354 |
Current CPC
Class: |
B63B
7/06 (20130101); B63B 7/04 (20130101); B63B
34/20 (20200201); B63B 34/23 (20200201); B63B
2007/003 (20130101) |
Current International
Class: |
B63B
7/04 (20060101); B63B 7/00 (20060101); B63B
7/06 (20060101); B63B 35/71 (20060101); B63B
007/00 () |
Field of
Search: |
;114/352,353,354,357 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Morano; S. Joseph
Assistant Examiner: Wright; Andrew
Claims
What is claimed is:
1. A collapsible, rigid hull, sectional boat assembly, comprising:
a) a plurality of separate, individual, rigid, foldable hull
section members each forming a transverse segment of the bottom
hull and opposite hull side walls of an assembled elongated boat
hull, each said hull section member comprising: 1). a substantially
rigid sheet formed of a selected synthetic thermoplastic resin
material having predetermined, first hinge fold lines defining and
foldably dividing the sheet into at least one bottom hull panel and
a pair of opposite hull side wall panels foldable relative to each
other along mutual said first hinge fold lines between an operative
position forming a transverse segment of a boat hull configuration
and a collapsed, folded, storage condition in which said hinged
panels are disposed in substantially stacked condition, and 2). a
pair of opposite rib flaps on each said hull panel formed by
opposite, second hinge fold lines positioned on the sheet a spaced
distance inwardly of and extending along the opposite,
commonly-shared terminal edges of each said hull panel, said second
hinge fold lines arranged to permit each said opposite rib flap to
be folded into an operative condition extending substantially
perpendicularly relative to the plane of the surface of its
corresponding hull panel, b) a plurality of substantially rigid rib
cap members configured to supportingly engage corresponding rib
flaps of adjacent hull panels of adjacent hull sections and
releasably secure said plurality of hull sections together in
predetermined elongated hull configuration, c) securing means for
releasably interengaging and securing said rigid rib cap members
and said adjacent corresponding rib flaps together to secure said
plurality of hull sections together into a complete, rigid,
elongated boat hull, d) a plurality of rigid, foldable top deck
section members each comprising a rigid sheet formed of a selected
synthetic thermoplastic resin material having first hinge fold
lines forming panels configured to allow the deck section to fold
in order to overlie at least the top edge of a selected hull side
wall panel and be releasably secured to at least one face surface
of the selected hull side wall panel, each said top deck section
having second hinge fold lines forming at least one pair of
opposite deck attachment flaps configured to engage a pair of rib
cap members for releasable securement of the top deck section
member therebetween, e) securing means for releasably interengaging
and securing said rigid rib cap members and corresponding deck
attachment flaps together to releasably secure said plurality of
top deck section members between said plurality of rib cap members,
and f) means for preventing the passage of water between adjacent
hull section members into the interior of the boat when the boat is
on a body of water, whereby g) the plurality of said hull and deck
section members and rib cap members may be quickly and easily
assembled into a complete rigid hull boat for use on a body of
water and also quickly and easily disassembled, each hull and deck
section individually folded into collapsed, stacked condition for
extremely compact storage and convenient transport in a carrying
bag or backpack.
2. The collapsible rigid hull boat assembly of claim 1 wherein said
hull section members are formed of sheets of corrugated
plastic.
3. The collapsible rigid hull boat assembly of claim 1, wherein
said top deck section members are formed of sheets of corrugated
plastic.
4. The collapsible rigid hull boat assembly of claim 1 wherein said
means for preventing passage of water comprises a gasket seal
interposed sealingly between adjacent hull section members forming
the assembled, elongated rigid boat hull.
5. The collapsible rigid hull boat assembly of claim 1 wherein said
means for preventing passage of water comprises a flexible,
water-impervious, fitted fabric boat cover configured to be secured
to the boat in condition fully enveloping and covering at least the
entire exterior hull surface of the boat.
6. The collapsible rigid hull boat assembly of claim 5 wherein said
fitted fabric boat cover is further configured to also envelop and
cover the exterior top deck surface of the boat.
Description
FIELD OF THE INVENTION
The present invention relates to a design system for building
folding boats, and more particularly to a ultra lightweight
collapsible, easily transportable, easy-to assemble Kayak with a
structurally secure monocoque, rigid hull and deck system.
Eliminating the use of the traditional rib and stringer skeletal
frame with outer skin. This is achieved through an improved hull
design and construction method and the unique state of the art
materials used therein.
BACKGROUND OF THE INVENTION
So called "folding boats", kayaks and canoes have been known for
hundreds of years but hitherto have been constructed using the
conventional methods of skin over wooden frame or more recently
treated canvas or nylon material stretched over an aluminum frame.
This creates a very heavy, complicated, craft, which is ill-suited
for lightweight back packing, simple quick assembly and small space
storage.
DESCRIPTION OF PRIOR ART
Disadvantages of these conventional methods include increased hull
drag, which reduces speed and increases expended effort by the
paddler. This condition is caused by the lack of inherent support
between the hull stringers. (E.G. U.S. Pat. No. 4,821,666 HULL
CROSS SECTIONS) which allows the skin to flex inward under water
pressure and create pockets and ridges to disrupt the smooth flow
of water across the hulls bottom surface. In addition, there is
excessive hull flexure inherent in the skin over frame construction
that allows the hull to distort its shape as waves pass under it
again causing increased drag, paddle effort and friction ware on
components. This creates the need for heavier skin materials and
more maintenance.
The conventional frame construction methods (E.G. U.S. Pat. No.
4,841,899 WOODEN FRAME AND HARDWARE PIECES), by their inherent
design require a high number of wood, plastic, and metal
components. (Over 250 in U.S. Pat. No. 4,4841,899). These
components increase the complexity, cost, weight and assembly time
of this method. Included in the more recent conventional frame and
skin folding boats, kayaks and canoes is the use of inflatable
sponsors or devices needed to strengthen the hull structure and
tighten the skin. These devices also increase total weight, while
adding cost in an attempt to create a more ridge hull and
eliminate/replace hull flexure. (E.G. U.S. Pat. No. 4,751,889 FIG.
2 ITEMS 60 AND 61) Other drawbacks to following the traditional
skin over frame concept with canoes, kayaks, dinghies, and other
small boat designs are the shear bulk and weight of these vessels.
This often necessitates more than one storage container or bag and
the weight of these craft's restrict their use as a true back
pack-able boat to be taken along with the necessary camping gear
for extended times or distances by a single person. This creates
the need to leave important camping gear behind because of the
weight or bulk of current folding boat conventional designs.
Maintenance is another concern with the conventional skin over
wooden and aluminum frames. The user must continually inspect and
carefully refinish or otherwise provide a continual protective
coating on the wood, aluminum and metal components to prevent
delaminating of the wood, corrosion of aluminum and rust of any
other metal components.
Performance issues experienced with prior art include excess
flexibility in some canoes currently commercially available such as
Jensen U.S. Pat. No. 4,290,157. Other folding canoes, which are
similar to the Jensen design, have inherent structural weakness
that creates problems for users; such as when the paddler sits in
the center of the canoe with no weight in each end.
This creates excessive rocker making the hull form into a banana
shape. Conversely, if two paddlers sit one in each end of the canoe
the hull forms a reverse rocker, looking like an upside-down
banana. Both of these conditions create maneuvering and handling
problems along with excessive stress on the hull frame
structure.
Collapsible, portable, or folding boats disclosed in U.S. Pat. Nos.
3,869,743; 8,338,46; 2,053,755; AND 598,989 represent prior art
using extremely complicated hull frames that are complicated and
time consuming to assemble. They have a plethora of small loose
parts, rib connectors, and ancillary other components that are easy
to loose and difficult to use, adding time and frustration to the
assembly procedure. The added weight of this prior art make many
folding boats unsuitable for pack packing as disclosed in U.S. Pat.
Nos. 381,137; 1,920,130; 4,290,157 FIG. 9: U.S. Pat. No. 4,751,889;
FIG. 3 thru U.S. Pat. No. 6; 1,920,130; 3,004,370; 4,110,951 and
3,932,049 represent a wide variety of fasteners used for securing
tubular components within an assembly. There is a common thread
woven through all of these connectors and that is their high cost,
complexity and some are not well suited for their use in
collapsible portable watercraft frames and are known to fail during
use. They also represent higher component and installation costs to
the folding boat manufacture and this cost is passed on to the end
user. Folding dinghy's disclosed in U.S. Pat. Nos. 4,124,910;
4,697,540; 4,250,583 fold but do not totally disassemble into a
small package suitable for transportation in a car trunk or boat
cockpit locker and their weight limits their use for back
packing.
Collapsible boat U.S. Pat No. 2,994,891 represents the skin and
frame prior art and therefore enjoys the same limitations of
weight, size, complexity, high manufacturing costs, small space
storage, transportation and back packing capability.
Foldable boat U.S. Pat. No. 5,975,005 this prior art uses rigid
hull forming sections with a separately attached hinging system to
facilitate folding of the hull forming sections. A special molded,
interlocking engagement projection configuration is used to join
the hull forming sections together in an effort to add lateral
strength to the assembly and capture the ends of the hull forming
sections into a unit. The materials listed (I.E. Aluminum titanium,
rigid wood, fiber-reinforced plastic, epoxy, polyester,
polyethylene, resins reinforced with glass fiber, carbon fiber or
the like) are all materials requiring special machining, molding
processes and tooling, which are all specialized, expensive
materials and manufacturing processes. The flexible members, and
tightening piece and hooks used to assemble the foldable boat and
hold it together present some risk to the boat operator if one of
the top, side flexible members loosen or lets go. This would
potentially allow the water pressure to push in the side allowing
water to enter the boat in large quantities over the topside of the
hull forming side member. Other limitations of this prior art are
the box shape and potential for use of more streamlined hull shapes
used in dinghies, kayaks and canoes. High flotation loss due to the
volume and weight of the hull forming members and assembly flexible
members and hardware, will reduce the total load carrying
capacity.
In summary, this prior art employs a design and materials that
limit its application to basically box type boat shapes that are
heavy, have little aesthetic appeal and would not be suitable for
use in canoe, kayak, dinghy, or other folding watercraft, used in
backpacking or light weight folding water craft, used in
backpacking or light weight folding boats construction and
manufacturing.
SUMMARY OF THE INVENTION
It is the object of this present invention to overcome the
disadvantages of the prior art and provide a collapsible kayak,
canoe or folding boat that is super light weight with a rigid hull
having a minimum of components that will provide performance more
typical of non-folding rigid hull watercraft.
It is also the specific goal of this present invention to provide
here-to-fore unattainable hull rigidity with the inherent
lightweight and simplicity of construction and assembly needed in
higher performance lower cost portable watercraft. It is also the
specific goal of this present invention to eliminate the use of the
traditional skeletal frame with all its separate support members,
clamps and special complex fasteners through the novel use of
extruded corrugated high density plastic sheet coupled with a
unique simple method of constructing semi-rigid hull and deck
sections for folding, portable, light weight watercraft.
It is also a specific object of this invention in connection with
the construction of a folding boat, canoe, dinghy or kayak, to
provide by incorporation of extruded corrugated plastic, enhanced
resistance to hull and skin flexure with improved through the water
performance more like a rigid hull shell than a folding boat.
It is also a specific object of this invention to reduce flotation
loss and increase load carrying capacity through the unique use of
light weight extruded corrugated, high-density plastic sheet and
elimination of the skeletal frame and its components reducing the
total weight of the watercraft thus increasing the load carrying
capacity of the watercraft.
It is further the specific object of this invention to eliminate
the unsupported hull skin areas allowing for a lighter waterproof
skin with fewer reinforcements, lighter weight and elimination of
the need for air-bladder skin tightening and hull strengthing
systems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the monocoque kayak hull without
the waterproof cover taken from the rear and above.
FIG. 1 is top view of the kayak hull with seat.
FIG. 3 is a top view of the hull with the waterproof cover
installed.
FIG. 4 is a side elevation view of the kayak of the invention, from
the starboard side.
FIG. 5 is a view similar to FIG. 4, but showing the bow section of
the hull aligned and inserting into the waterproof cover.
FIG. 6 is a perspective view looking through the hull (hidden view)
at the rib cap, hull and deck assembly ten from the port side rear
and above.
FIG. 7 is a top view of a typical hull section in the flat pattern
unfolded state.
FIG. 8 is a perspective view of the hull section in FIG. 7 in the
folded state ready for assembly with the rib cap and next hull
section.
FIG. 9 is a cross sectional end view showing the configuration of
the extruded hull and deck corrugate plastic material.
FIG. 10 is a hidden line perspective view showing the construction
details of a typical rib cap.
FIG. 11 is a perspective view of a typical rib cap.
FIG. 12 is a cross section view through a typical fabricated rib
cap assembly showing the assembly of two hull sections.
FIG. 13 is a cross section view through a typical fabricated rib
cap assembly having a rubber gasket set to eliminate the need for a
waterproof cover.
FIG. 14 is a perspective view of the 12-foot basic Omni-Canoe
FIG. 15 is a perspective view of a 14-foot Omni-Canoe with one
center section added.
FIG. 16 is a perspective view of a 16-foot Omni-Canoe with
two-center section added.
FIG. 17 is a perspective view of the faired kayak hull with
modified deck sections converting it into a canoe.
FIG. 18 is a perspective, hidden line view of a pitched tent using
the kayak or canoe components with a tent shaped cover.
FIG. 19 is a perspective view of the yacht tender, pram or dinghy
designed and constructed using the present invention technology,
materials and fastening system.
1 #1 Rib Cap Assembly 2 #2 Rib Cap Assembly 3 #3 Rib Cap Assembly 4
#4 Rib Cap Assembly 5 #5 Rib Cap Assembly 6 #6 Rib Cap Assembly 7
#7 Rib Cap Assembly 8 #1 Hull Section 9 #2 Hull Section 10 #3 Hull
Section 11 #4 Hull Section 12 #5 Hull Section 13 #6 Hull Section 14
#7 Hull Section 15 #8 Hull Section 16 #1 Deck Section 17 #2 Deck
Section 18 #3 Deck Section 19 Port Deck Section 20 Starboard Deck
Section 21 #6 Deck Section 22 #7 Deck Section 23 #8 Deck Section 24
Floor Boards 25 Water Proof Cover 26 Entire Boat 27 Bow (Forward)
28 Stern (Aft) 29 Seat and Back Rest 30 Arrow - Direction of
movement 31 Port Side 32 Starboard Side 33 Shock Cord Drawn String
34 Slide Cam Lock 35 Rib Flaps 36 Bi-Fold, Accordion Section 37
Cinch Strap 38 Web Belt Anchor 39 "D" Ring 40 Hook and Loop
Fastener 41 Rib Cap Fastener Holes 42 Nylon Thumbscrew 43 Nylon
Wing Nut 44 Extruded Plastic Channel 45 Gasket Seal 46 Cockpit 47
Hull Assembly 48 Deck Assembly 49 Flap Fastener Holes 50 Hinge
Score Line 51 Boat Bottom 52 Deck Attachment Flaps 53 Rib Cap Front
Side 54 Rib Cap Rear Side 55 Rib Cap Cross Member 56 Parallel
Surface Sheets 57 Vertical Ribs
DETAILED DESCRIPTION OF THE DRAWINGS
Referring in detail to the drawings, and particularly FIGS. 1, 2, 3
and 4, the FOLDING KAYAK of the invention is indicated in its
entirety at 26. In various ones of the figures, an arrow applied,
for convenience, to indicate direction of movement, and thus
orientation of the kayak. The kayak includes a bow 27, a stem 28, a
starboard side 32, and a port side 31. It has a cockpit or 46 to
accommodate passengers.
The FOLDING KAYAK includes a hull 47; a deck assembly 48, and a
waterproof cover FIG. 3,25. The present invention, folding kayak,
is composed of twenty-three primary components, namely hull
sections, eight deck sections and seven rib caps. As will be seen
in FIG. 6 the eight-section hull is generally referenced 47, and
the eight deck sections 48 with the rib caps indicated #1
through#7.
A basic embodiment of the present invention built according, to the
structure, materials and methodology, described herein, is a kayak
as shown in perspective views in FIG. 1 and 6. It comprises a
system of three major sub-systems: a waterproof cover system FIG.
5, 26; a monocoque hull FIG. 1,47 a deck assembly 48, and a rib
cap, hull and deck fastening system FIG. 6, #1 through #7 with
fasteners FIGS. 42 and 43. FIGS. 3, 3a, 3b, 7, 8, 10, and 12 show
details of the three sub-systems.
1. Monocoque hull and deck
The hull 47 and deck 48 seen in FIGS. 1, 2, 4 and 6 are constructed
form extruded corrugated copolymer polypropylene and polyethylene
high impact and high density plastic sheet FIG. 9 consisting of two
flat sheets 56 connected by vertical ribs 57. The hull sections
being individually identified 8 through 15 include separate
sections detachably and releasable secured together. Each hull
section FIGS. 1 and 4, 8 through 15 are cut out in a flat pattern
FIG. 7 having an outside peripheral shape with fasteners holes 49,
rib flaps 35 and hinge score lines 50. The flat blank hull section
FIG. 7 of hull section 13 is then folded up into the hull assembly
shape FIG. 8 by folding the flat blank FIG. 7 at the hinge score
line 50 forming the "Living Hinge" and hull section 13, by creating
the ribs 35 boat bottom FIG. 3b, 51 along with port 31 and
starboard 32 sides. This same process is repeated for all hull
sections in FIGS. 1 and 4, 8 through 15. The deck sections seen in
FIGS. 1, 2 and 4 are individually identified 16 through 23. These
are constructed from extruded corrugated copolymer polypropylene
and polyethylene high impact and high-density plastic sheets, FIG.
9, and consist of two flat parallel surfaces 56 connected by
vertical ribs 57. The deck sections 16 through 23 include separate
sections detachably and releasable secured together. Each deck
section FIGS. 1, 2 and 4, 16 through 23 are cut out in a flat
pattern having an outside peripheral shape with rib flaps 35 and
deck attachment flaps 52, FIG. 3b and hinge score lines so the flat
blank deck section is folded up at the hinge score lines 50 forming
the "living Hinge" and the cross sectional shape FIG. 3b, hull
section 21 along with the rib flaps which are the same as shown in
FIG. 7, 35 and deck attachment flaps 52 for port 31 and starboard
32 sides FIG. 3b. This same process is repeated for all deck
sections FIGS. 1, 2, and 4, 16 through 23.
2. Rib Cap Fastening system
Looking at FIGS. 6, 10 and 11 you see the rib caps individually
identified as #1 through #7. The rib caps for this present art
kayak are constructed from suitable plastic material such as ABS
that can be either laser, rule die cut, or other manufacturing
methods discussed herein. FIG. 10 shows the rib cap #5 assembly
that supports the hull 47 and deck 48 at hull section 13 and deck
section 21 respectively as shown in FIG. 6. The two FIG. 1053 and
54 front and back rib cap sections are joined together with a
gluing process by cross members 55. FIG. 11 shows the clean lines
and simplicity of the finished rib cap #5 assembly an alternate
construction method is shown in FIGS. 12 and 13 where by an
extruded plastic channel 44 is cut to length and glued around the
inside opening of the rib cap. Front 53 and rear 54 rib cap laser
cut side sections shown in FIG. 10 completing the simple strong
light weight assembly as seen in FIGS. 11 and 12. The hull 47 and
deck 48 sections, having been folded into their respective shapes
FIGS. 8 and 3b, are then aligned with each other so that the folded
up rib flaps 35 as shown in FIGS. 12 and 13 are butted up against
each other. The rib caps FIG. 6 #1 through #7 are then slipped over
each set of folded up rib sections and aligned with the fastener
holes FIG. 7,49. The nylon thumbscrew FIG. 12, 42, is slipped
through the rib cap #5 and hull section 12 and 13 assembly. The
wing nut 43 is now treaded onto the thumbscrew 42 and tightened.
This process is repeated at each of the seven rib cap stations FIG.
6 #1 through #7. The deck sections FIG. 1,16 through 23 are now
aligned over each respective hull section FIG. 1, 8 through 15. The
folded down rib flaps 35, FIG. 8 are aligned and slipped down into
the rib cap top section until it touches the tops of the rib caps
as shown in cross section in FIG. 3b.
Now the deck attachment flaps FIG. 3b, 52 having hook and loop
fasteners 40 are pressed down against the corresponding port 31 and
starboard 32 hull sides also having hook and loop fasteners to
complete the assembly. Referring to FIG. 13, another alterative
method to creating a waterproof hull without using a waterproof
cover is to add a gasket seal 45 in between the fold up rib
surfaces 35 to create a waterproof seal and eliminate the use of
the waterproof cover 25, FIG. 3, thus reducing the kayak weight by
approximately three additional pounds and reducing the total back
pack folded down weight to around thirteen pounds.
3. Waterproof Cover System
Referring to FIGS. 3, 3a and 3b shows the embodiment of the
waterproof cover for the present art lightweight folding kayak FIG.
1,26. The waterproof cover FIG. 3,25 comprises a plurality of
panels cut to a specific shape from suitably strong and flexible
material having a waterproof coating and commonly used for kayaks,
canoes and inflatable boats. These panels are sewn together and may
be heat-sealed or seam-sealed using a coating in a separate
operation on the sewn seams as with tent seam-sealing using a
seam-sealing liquid applied to the sewn seams to prevent leakage.
The folding kayak waterproof cover 25 utilizes a single split entry
section down the center of the aft deck section 28. This split
section uses hook and loop fastening FIGS. 3,3a and 3b, 33 to
maintain light weight and facilitate closure of the aft deck cover
and create a snug fitting relation of the cover to the hull 47 and
deck 48 assemblies FIGS. 1 and 6. At the aft end 28 of the
waterproof cover 25 is a unique Bi-fold cover tightening system
FIG. 3a, consisting of an accordion shaped extended hull cover
section 36 that is adjusted and held in place by the cinch strap 37
which is looped through a "D" ring 39 fastened to the waterproof
cover by web belt anchor 38. The waterproof cover tension can be
adjusted to compensate for stretch or shrinkage by adding to or
releasing the tension on the cinch strap 37 and then pressing the
cinch strap 37 back against itself to engage the hook and loop
fastener system 40 to maintain the adjustment position of cinch
strap 37. The cockpit or hatch FIGS. 1,3, and 4,46 shape and
adjustment is accomplished by tightening the shock cord drawstring
and maintaining the adjusted position of the drawstring with the
slide lock 34.
4. Versatility of the Invention by Ease of Assembly
The versatility of the present invention is illustrated, in part,
by appreciating the following detailed description of how one can
assemble the folding kayak of the present invention. Lay the
compact carrying bag on the ground and remove the stuff bag labeled
"Hull sections,". Remove hull bow 27, section 8, FIG. 1 and fold
into its designed shape. Remove hull section 9 and fold it into its
designed space and place next to the bow section on the ground so
that the rib flaps 35, FIG. 8 are adjacent to each other. Remove
rib cap #1, FIG.6 from the stuff bag labeled "rib caps," and slip
over hull sections 8 and 9 rib flaps 35. Align rib flap fastener
holes 49, FIG. 8 with the rib cap fastener holes 41, FIGS. 10,11,
and 12. Slide the nylon thumbscrew fastener 42, FIG. 12 through the
rib assembly until the nylon thumbscrew 42 is flush against the rib
cap surface 54, FIG. 13. Now, thread the wing nut fastener 43,
FIGS. 12 and 13 onto the nylon thumbscrew fastener 42 until snug.
Align and install the remaining nylon thumbscrews 42 and wing nut
fasteners 43 into the #1 rib cap assembly. The same procedure is
used six more time to assemble the remaining rib caps #2 through
#7, FIG. 6 with the hull sections 10 through 15, FIG. 1. You now
have the completed hull assembly 47FIG. 1 sitting on the ground in
front of you ready for the deck assembly 48, FIG. 1. Remove the
stuff bag labeled "deck sections" from the carrying bag, open it
and remove deck section 16, FIG. 1 and fold it into its designed
shape with the deck attachment flaps 52, FIG. 3b pointing down at
the ground. Align deck section 16, FIG. 1 over hull section 8, FIG.
1 and slip rib flaps 35 down into rib cap #1, FIG. 6, top section
until it touches the top of the rib cap as shown in the cross
section in FIG. 3b. Fold down and in the deck attachment flaps 52,
FIG. 3b having hook and loop fasteners 40 and press in against the
hull section 8, FIG. 1 port 31 and starboard 32 sides also having
hook and loop fasteners to lock the hull section 8, deck section 16
and rib cap assembly into one ridged unit. In succession remove the
remaining deck sections 17 through 23 from the stuff bag and follow
the same procedure until all hull 47 and deck 48 components are
assembled as a unit into a rigid monocoque kayak assembly ready for
the waterproof cover.
Remove the waterproof cover 25 from the carrying bag and open the
aft single split entry by separating the hook and loop fasteners
40, FIGS. 3 and 3b and loosen the shock cord drawstring 33, FIG. 3
then place the cover on the ground, unrolled with the open side up.
Lift the assembled kayak 26 and align it above the waterproof cover
so that the bow 27 of the assembled kayak and waterproof cover are
both pointing in the same direction of arrow 30. Now slip the bow
27 of the kayak into the bow section 27 of the waterproof cover 25,
FIG. 5 and align the cover while pulling it onto the front section
of the kayak until the cover is pulled tight with the bow end 27
and you can see a tight fit with the foreword deck and hull
sections. Slip the aft 28 single split entry section of the
waterproof cover up over the aft 28 end of the kayak and adjust so
that the entry edges will align with the centerline of the kayak
when you refasten the hook and loop single entry fastener 40, FIGS.
3 and 3b. Adjust the waterproof cover tension by tightening the
cinch strap 37 over the bi-fold flaps and secure in place by
pressing the hook and loop fasteners 40, FIG. 3a together to
complete the assembly. Tighten the waterproof cover around the
cockpit 46, FIG. 1 by adjusting the tension of the shock cord
drawstring 33, FIG.3 and locking it in place using the slide cam
lock 34. Complete assembly of the kayak by placing the floor boards
24, FIG. 1 in the bottom 51, FIG. 3b of the inside of the cockpit
46, FIG. 1 these are held in place by the rib caps #3, #4 and #5,
FIG. 6. Place the seat and backrest 29, FIGS. 2 and 3 into position
so they engage the hook and loop fasteners that hold them in place.
Put on your personal flotation device (PFD) pick up a paddle,
launch the kayak into the water, get in, paddle and go have
fun!
From all of the above the reader will see that the present
invention is a versatile structure and methodology for building
lightweight, easy to transport, easy to assemble folding
watercraft. While the description of the basic embodiment of the
invention, a kayak, is described in detail, it is only one
embodiment among many possible ones. It should not be construed as
a limitation on the scope of the invention but as an
exemplification of one preferred embodiment thereof Other exemplary
embodiments are illustrated in FIGS. 14, 15, 16, 17, 18 and 19 and
discussed herein.
The present invention describes material, structure and methodology
to build a variety of rigid-hulled lightweight folding boats such
as kayaks, dinghies, row boats, open canoes, yacht tenders, prams,
kick and pontoon boats. Such craft, and many others, are included
within the scope of this invention. The present invention is a
totally new state-of-the-art concept, which has produced several
individual improvements new to the building of foldable watercraft.
These improvements actually generate a design and construction
system that when this technology is applied to a boat it places it
into the category of a new lightweight generation of folding boats.
The basic embodiment discussed herein is a kayak. The shape of the
present embodiment of this invention is representative of many
modem kayaks being constructed today and can best illustrate the
application of this new construction system. However, many other
very different embodiments are described in the section on
representative alternate embodiments to illustrate the broad range
of the potential applications of this system. These alternative
embodiments include additional kayak designs and other types of
watercraft. The advancements and improvements of the present
invention over prior art in the present embodiment of a folding
kayak are as follows.
1. Materials use as Key to the Present Art Construction System
The material of an ultra light weight hull must minimize weight
without sacrificing strength or economy of manufacture, this
material must also possess the ability to be shaped into hull and
deck forming sections with the integral ability to flex or hinge at
section forming joints thus eliminating the frame and stringers of
conventional folding boats that provide reinforcement through these
frame assembly's. To that end, state-of-the-art copolymer,
polypropylene and polyethylene high-impact and high-density
plastic, in extruded thin wall corrugated sheets has been tested
and selected as the material able to meet this present art design
and performance requirements. This material is referred to by brand
names such as: Hi.about.CORE.RTM., COROPLAST.TM., COREX,
PLASTICORE.RTM., BIPLEX and others. Corrugated thin wall plastic is
a one-piece process extruded sheet consisting of two flat sheets
connected by vertical ribs. This material is super-rugged and
extremely lightweight.
Unaffected by water, it will not rust, corrode, rot or mildew; it
is virtually tear-proof, withstands wide temperature variances,
resists puncturing, high impact damage and is designed for harsh
outdoor weather conditions. This material is chemically inert with
a nil pH factor making it environmentally sound. It is waterproof,
floats, stain- resistant, can be flexed an unlimited number of
times without breaking. This unique ability is called "A Living
Hinge". All of the elements and benefits hither to discussed about
the corrugated, light weight, thin wall, plastic material are key
factors, or the heart of the present art, and is responsible for
making this unique ultra light, no skeletal frame, rigid hull,
folding boat construction system possible.
2. Low Cost Hull and Deck Manufacturing Methods
The choice of extruded corrugated plastic for the present art and
other watercraft types and designs included in this patent. Is
based, as well, on its ability to be easily precision CNC laser or
die cut. The manufacturing method intended for use herein the
present art is a "RULE DIE". The "RULE DIE", on a flat bed press
will produce extremely accurate CAD designed boat hull and deck
sections with all critical bend creases in one press stroke. The
present art uses three four by eight extruded plastic sheets.
Therefore, for every three strokes of the press there is one
complete present art light weight folding kayak produced,
satisfying the present art goal of introducing lightweight folding
kayaks and other water craft included in this patent at an
extremely low manufacturing cost, because of the high reduction in
manual labor normally associated with prior art conventional skin
on skeletal frame construction. In addition to the low
manufacturing costs the extruded plastic sheet cost in volume in
higher quantities are under ten dollars at present. Therefore
making it possible for the present folding kayak and the other
watercraft included in this patent to be sold for a much lower
price than the conventional folding watercraft prior art. Making
possible the enjoyment of the paddling water sport available to
many more people who cannot afford the thousand plus dollars needed
to purchase most of the modem day folding kayaks, canoes and other
watercraft available today.
3. Rigid Monocoque Hull and Deck with Integral Hinges ("The Living
Hinge")
The unique ability of extruded corrugated plastic to have the
stiffness of thin plywood yet having the quality to be creased and
bent to form "the living hinge" facilitates the construction of the
hull and deck section in what is termed the "flat Bank". These
"Flat Blanks" having the outside perimeter precisely cut to the
correct size and the bend lines precisely embossed in the correct
location, so that when the "FLAT BLANK" is folded up into its hull
section shape, creating the integral ribs by use of the "living
Hinge". These folded up hull sections are then joined together with
the plastic rib caps and nylon fasteners. The deck sections, having
been precisely cut to the correct outside perimeter with the
precision located embossed bend lines, are folded up into their
proper deck section shape and located over the corresponding hull
section. The integral deck stiffeners and fastening flaps are
located inside of the rib caps and outside of the hull gunwale
respectively. The fastening flaps are folded down and pressed
against the gunwale to engage the corresponding Velcro (a brand
name) hook and loop fastener strips affixed to the outside hull
gunwale and the inside of the deck section fastening flaps to join
the hull and deck sections into a non-flexing, rigid, monocoque
kayak hull and deck assembly.
4. Rib Cap System
The hull sections, having been folded into their respective hull
shape, are then aligned with each other and the rib caps are placed
over the integral ribs to encapsulate them within their "U" shape.
Nylon thumbscrews are then passed through corresponding holes in
the rib caps and the integral hull section ribs then tightened with
a wing nut to clamp the hull sections together. The rib clamps also
clamp the deck sections by their deck stiffeners creating a
monocoque assembly. In addition to the clamping function the rib
caps add radial and axial strength to the hull and deck sections
preventing flexure and movement of the folding kayak assembly.
Construction of the rib caps is accomplished for the present art
with CNC laser cut ABS plastic components fastened together in a
fixture. However, construction is not limited to this method as
glass fiber cloth and epoxy clamped in a mold has produced these
rib caps as well. Other processes such as plastic injection
molding, rotational-molding, rule die cutting, and many other
methods are capable of producing these components. The choice is
driven by component weight, volume, quality and economics.
5. Waterproof Cover
The function of the waterproof cover with the present invention is
not to create the hull shape, outer boat skin or add strength to
the hull as it is normally employed in prior art. On the contrary,
the primary function of the waterproof cover is to seal out water
from entering between the rigid hull and deck sections and to add
esthetic value to the folding watercraft. It is desirable to have a
waterproof cover for a folding kayak or water craft which is very
light in weight, waterproof and strong, yet is simple and
inexpensive to manufacture. It is a high priority to minimize the
weight of all materials in the covers construction since this will
enhance the portability of the kayak or watercraft. The simplicity
of design for the present art cover makes repair under wilderness
conditions very simple and easy with minimum tools and materials.
The present art cover utilizes a single split entry section down
the center of the aft deck section. This split entry section uses
Velcro (a brand name) hook and loop fastening to maintain light
weight and facilitate closure of the aft deck cover and create a
snug fitting relation of the cover to the hull and deck assembly.
At the aft end of the waterproof cover is a unique cover tightening
system with Bi-fold flaps and tightening strap to apply a linear
pull along the kayaks centerline axis. Thus allowing for loosening
and tightening of the cover during wet, dry, hot or cold conditions
causing material shrinkage or stretch. This bi-fold flap system
coupled with the aft deck cover opening, enhances the ease in which
the assembled boat hull is slid into the cover and the aft deck
cover is closed and sealed with the hook and loop fastener. The
material for the cover chosen after extensive research and testing
are Cordura (a brand name by Du Pont) a high density nylon cloth
with a urethane water barrier used by the military for many tough
applications including boot uppers. Cordura nylon cloth is known as
the standard for toughness; abrasion and scuff resistance puncture
and tear resistance in hard use and extreme out door conditions.
Abrasions resistance is the greatest concern for the durability and
long-term life of this present arts waterproof cover and tests have
shown that Cordura will last three times longer than standard nylon
cloth. The second material selected for the areas above the water
line, including the deck, is a 3.5-ounce lightweight; rip stop
nylon cloth with a urethane water barrier coating. The combination
of these two materials create a very light weight waterproof cover
that is tough, easy to slip into and off of the present art kayak,
conforms to the hull shape and adds great esthetic value to the
water craft while most importantly preventing water from entering
the light weight, folding, kayak or watercraft.
6. Unique Faceted Hull Shape
A key element to the streamlined or fair hull shape of the present
invention is the ability to form the extruded corrugated plastic
hull and deck material into a non-boxy shape. A streamlined hull
that will offer little resistance to movement through the water is
attained by breaking a given hull shape into increments. Then
creating a blend of compound angles along with the grain or flute
direction of the extruded plastic and forming the material into
faceted surfaces that create a continuous smooth transition and a
fair hull form stem to stern. These compound angles are designed
into the hull and deck section flat blanks to achieve the smooth
hull transitional shape when folded up into their correct hull or
deck shape and held in place with the rib caps.
7. No Metal Components to Rust or Corrode
Unlike prior art folding boats that have used many complicated
aluminum and steel components and fasteners that are subject to
either rust or corrosion. The present invention has utilized all
state-of-the-art plastic materials and fasteners eliminating the
need for careful maintenance. The use of theses plastic materials
and fasteners also drastically reduces the weight of the folding
boat making it more portable with a backpack.
8. The Assembled Kayak
The unique blend of material usage (extruded corrugated plastic)
and present art folding boat design concept. Has eliminated the
need for the traditional skeletal frame used heretofore in prior
art. The benefits of this in the present invention are the huge
reduction in the quantities of components. The total number of
components has been reduced in this present art to twenty-seven
major hull deck rib cap and cover components. The advantage of this
improvement over prior art whose number of components often exceeds
200 is obvious as you experience the simplicity of the present
inventions assembly. You simply fold each hull section up into its
designed shape starting with hull section #1, then fold up #2 hull
section and place next to #1 section and slip the rib cap over the
integral hull section ribs, insert the nylon thumb screw, then
tighten. You then repeat this process six more times. Then you fold
the deck sections into their designed shape.
Starting with deck section #1 and inserting the integral deck
stiffeners into the rib cap and folding the fastening flaps down to
attach to the corresponding hull section. You now have a rigid
monocoque kayak assembly ready for the waterproof cover. Open the
single split entry in the aft end of the waterproof cover and
easily and quickly pull the cover over the hull beginning at the
bow end aligning the cover as you slip it on. Then attach the
Velcro (a brand name) hook and loop fastener on each half of the
opening to close up the aft deck entry section. Adjust the bi-fold
flaps cover tightening straps and cockpit drawstring to tighten the
cover around the cockpit and the assembly is complete in just a
matter of a few minutes. Disassembly of this kayak is much quicker
than the assembly. You simply loosen the cockpit drawstring,
bi-fold strap; open the aft cover and slip off the waterproof cover
quickly and easily. Release the deck fastening flaps and lift off
the deck sections. Remove the nylon thumbscrews lift off the rib
caps, unfold the hull forward deck sections and the disassembly is
complete in minutes. With the disassembly complete, the components
are arranged inside of the compact carrying bag for portage or
storage for the next adventure.
9. Design Attributes and Safety
In addition to the unique faceted hull shape that allows the
creation of a smooth transition hull from flat rigid materials. The
present invention is an optimized blend of length, width and hull
shape. Using various elements from design perimeters used in the
development of kayaks, canoes, dory's, and the inventor's personal
experience to generate what is believed to be the optimum blend for
the enjoyment and safe operation by novice and experienced water
adventures. The hard chine hull shape was chosen because of the
many performance and safety factors associated with its design.
Hard chine boats resist being pushed off course by waves hitting
the hull at an angle. The hard chine boat has good initial
stability and resists being tilted. In addition to the initial
stability, as the hull is tilted, in rough water conditions, the
angled sides and deck offer secondary and tritary flotation,
contributing to overall stability. The combination of a wider hull
shape allowing the boat to sit higher in the water and the rocker
designed into the hull allows the boat to turn and maneuver quickly
making it very responsive to the paddler while still possessing the
ability to track well in a straight line while touring. Although
the hull and decks are technically rigid, the amazing property of
the extruded corrugated plastic material is the ability to allow
the kayak to absorb shock and impact from collisions with
obstacles. Then because of the inherent flexibility, the material
returns back to its original shape. Another unique fact about the
use of this extruded corrugated plastic material is that it creates
a double hull. This instills added safety in that the double hull
is filled with air between its walls adding to the positive
flotation of the craft in a capsized situation. In addition, the
polyethylene material used to manufacture extruded corrugated
plastic has positive buoyancy adding to the overall flotation of
the boat. Unlike the prior art using a sketial frame with a
waterproof skin cover. If you get a sever long tear in the kayaks
skin that may not be field repairable you have no alternatives to
fall back on but to get a ride from another boat, swim to shore or
walk back to civilization. However, with the present invention, if
the waterproof cover is damaged beyond field repair capability, all
is "Not" lost. Using Duck tape (a brand name) from the repair kit,
just wipe the water off of the areas on the outside of the bottom
of the hull at each hull section joint. Apply the two-inch wide
tape over each section joint and the bow and stern fold areas and
you have a waterproof vessel capable of taking you out to safety.
Another safety feature is the protection you get from the double
wall hull material. In the event you hit a bad snag and cut through
the first wall of the hull you have a second wall to maintain the
strength and water tightness of the vessel.
10. Ultra Light weight Simple Kayak
The primary goal of the present invention is an ultra light weight
water craft embodied in the present art kayak that weighs less than
fifteen pounds, making it suitable for extended distance and
difficult terrain backpacking. This goal has been achieved through
the use of extruded corrugated plastic and all lightweight plastic
components and fasteners. The secondary goal is simplicity of
manufacture and assembly. This goal has also been achieved in the
present art by limiting the number of hull, deck rib cap and cover
assembled components to twenty-four plus nylon fasteners.
11. Development of New Boat Designs Using All or Parts of this
Invention
The present invention has been disclosed in the form of a kayak,
which is a type of covered canoe maneuvered with the use of a
double paddle, by a single occupant. However, it should be
understood that this invention could readily be modified and
adapted to various types of watercraft, and is not limited to the
specific features shown. For example, with the addition of four
additional center sections, three rib caps, and a longer waterproof
cover the single occupant kayak described herein is transformed
into a double occupant kayak. Also, by replacing the covered deck
sections with narrow deck sections and a modified waterproof cover
you create a lighter weight open canoe. These three variations, a
single and double kayak and open canoe are all possible from a
single hull design using the unique modular concept of the present
invention. Through the expansion of this concept it is possible to
create rigid hull folding lightweight twin-hulled catamaran type
watercraft, dinghies, rowboats, yacht tenders, prams, kick and
pontoon boats, and canoes. Such watercraft and many others are
possible applications for the present inventions unique material
and modular construction systems. The system provides a simple
user-friendly environment for the rapid development of new model
designs from this unique technology, by allowing the developer to
make his layouts right on the hull and deck material. Then cutting
out the flat blank shapes, scoring the bend lines and then folding
up the shapes all with simple hand tools. These hand made
prototypes are ready for water testing as soon as the waterproof
prototype cover and rib caps are installed. A major advantage in
the use of the elements and methodology of the present invention is
that it requires no intermediate tooling or processes as with
injection molding or hand laid up fiberglass plugs or molds. This
technology has created the capability for the manufacturer to move
directly from the manual drawings on paper, or CAD drawings, to the
hand layout and cut out method, or using a CAD, DXF, or IGES file
to laser cut the sections. This system allows for rapid development
of prototype folding boats and other products to be covered in
representative alterative embodiments, at very minimal costs with a
short time from concept, prototyping, testing and on to the
market.
12. Representative Alternate Embodiments
While the basic embodiment of the present invention is a
lightweight-folding kayak, which is described in detail, it
represents only one embodiment among many other possible ones. All
of the alternate embodiments are constructed and assemble in a
similar fashion as the present basic embodiment described
herein.
1. Canoe (This is the Canoe Made from the Kayak Hull)
FIG. 17 shows an isometric view of the assembled hull and deck
assembly of a canoe. It consists of a plurality of hull and narrow
deck sections fastened together with the rib cap system, hook and
loop, and nylon fasteners. The waterproof cover is slipped over the
assembled hull and deck and fastened with the hook and loop closure
at the aft end, and the cover is tightened with the cockpit
drawstring and the bi-fold tensioning system. This demonstrates
that it is easily within the technology of the present invention to
modify the deck of the preferred embodiment creating a canoe.
2. Omni-Canoe
FIGS. 14, 15 and 16 show isometric views of assembled folding
Omni-canoes of different lengths they consist of a plurality of
hull and narrow deck sections fastened together using the rib cap
system, hook and loop, and nylon fasteners. The waterproof cover
would be slipped over the assembled hull and deck and fastened with
the hook and loop closure at the aft end and the cover is tightened
with the cockpit drawstring and bi-fold tensioning system.
The design and construction of this alternate embodiment of the
preferred embodiment shifts away from the faired hull concept, and
uses simple straight lines with fewer angles with the forward and
aft sections being a mirror of each other or absolutely
symmetrical. Thereby creating an ultra simple and lightweight boat
that can be manufactured with fewer tools because the components
for one half are exactly the same for the other half By adding
additional common center sections and a longer waterproof cover it
is possible to convert one boat into various lengths.
3. Tent and boat Combination
FIG. 18 shows an isometric view of a pitched tent using the
components of the present invention reconfigured as a tent frame.
There are various parts of the United States and other countries.
Where many land trails are interrupted by waterways offering the
opportunity to paddle distances with much less effort than carrying
your camping equipment in a backpack. However, when the adventurer
must carry this equipment, he/she wants it to be as light as
possible for the portage. Therefore, having an ultra lightweight
watercraft that transforms into a tent frame using a one or
two-pound tent cover eliminates the need for making the decision,
"Do I backpack my folding watercraft or tent up to the high lakes
or across country?" Many tents used today have a total weight
greater than this folding boat and tent combination.
4. Dinghy and Pram
FIG.9 shows an isometric view of an assembled folding lightweight
dinghy. A dingy is most often seen being towed behind a sailboat,
strapped on the foredeck of an ocean going craft or on inland lakes
and waterways. Its primary use is to get from the sailboat to the
shore and back. Thus a lightweight, easily storable, inexpensive
dingy would be desirable to owners of sailing craft and campers
wishing to explore and fish quiet, remote lakes and inland
waterways. The present invention is intended to provide a folding,
lightweight, stable, easy-to-assemble boat that will meet these
requirements inexpensively. The design and construction of the
dinghy follows exactly the methods used to manufacture the present
invention embodiment. The only difference in the design is the
squared-off stem and in the case of a pram the bow section is
squared-off as well. The same materials, fastening methods and
manufacturing methods used for the kayak are used in construction
of the dinghy and pram. In addition, the present invention
technology is also well suited for the construction of rowboats,
yacht tenders and other similar shaped watercraft.
5. Catamaran Type Multihulled watercraft
Twin-hulled catamaran and trimaran type watercraft offer the user
advantages not found in single hulled watercraft. Mostly, these
multi-hulled watercraft are known for being a very stable platform
on which to fish, hunt, skin dive and run rapids. In this case, two
hulls are placed parallel to each other, but a distance apart, and
interconnected by a platform type of deck. The design and
construction of the hulls for this watercraft would be similar to
the present art kayak.
However, the open cockpit area would be closed over with a
continuation of the fore and aft decks. Making the top deck
sections a continuous surface to support the interconnection
platform deck and seat with provision for oar locks and foot rests.
In accordance with the present invention the platform deck would be
constructed for easy disassembly and folding so as to be packaged
similarly to the hulls for easy portage and backpacking. The
overall design for the hulls of this watercraft would be a
modification of the present embodiment maintaining the strict
principles of lightweight, strength, simplicity of assembly and
construction and low cost manufacturing.
6. Materials and Construction of a Monocoque Hull and Deck
By this point the reader can see that through the use of the unique
elements of the present invention and methodology that a wide
variety of watercraft can be designed, developed, and built rather
quickly and inexpensively. Through various combinations and with
the various embodiments of its extruded corrugated plastic, living
hinge, hull and deck sections, rib cap assembly method, and
waterproof cover with its bi-fold skin tensioning system. That a
wide variety of lightweight folding watercraft can be designed and
built. Some may employ a different subset of the elements as seen
in the alternate embodiments.
It can be appreciated from the above that this technology can be
adapted to building lightweight, folding, car top carriers,
waterproof boat boxes, fold down coolers, collapsible ice shanties,
utility sheds, dog houses, bird houses, play houses for kids and
rigid "folding camping tents".
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